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robbiethepainter
10-14-2011, 10:00 PM
This is how I make swords. I use stainless steel for the blades and different thicknesses of brass strips, sheets and tubing that I buy from my art supply store Blick's. I use steel instead of aluminum because of the ease polishing. I can also use thinner material and its stiffer. I may experiament with aluminum on some thicker blades but for these steel is the best.

First thing I do is draft out the pattern on the parts. This is really necessary if you are building more then one and they need to match.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-12_21-05-21_95.jpg

Next I cut out the pattern and stick it to the metal using double tack.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-12_21-05-38_572.jpg

I cut along the pattern using a dremel with a cut off disc. Im sure there is a better way but this is what I have at the moment.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-12_21-14-14_867.jpg

I refine the blade with a sanding drum till it fits the pattern I have drawn.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-12_22-13-02_295.jpg

Sand down the surface of the blade with a sanding disk using 220 grit. This even more refines the width of the blade and also rounds the edges. It cleans up the heavy scratches I may have caused during the grinding down of the edges.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-12_22-30-19_635.jpg

Polish the blade using a felt wheel and flitz polish. Be careful because it flings the polish everywhere. I rub it on, spin the wheel away from everything, then go to work polishing.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-13_20-05-38_928.jpg

I transfer the design of the tsuba the same way. And then using a toothed grinding like the one listed A.

http://faqlight.shopower.com/dremel-bits.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-13_20-13-17_37.jpg

robbiethepainter
10-14-2011, 10:01 PM
I grind in the details using a really small engraving bit. and also cut the slot for the blade. And test fit the blade.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-13_20-17-21_431.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-13_20-31-12_742.jpg

0.005 thick sheet brass is cut into a thin strip. I wrap that thin brass around the area of the blade that will touch the tsuba. I brush in a little flux as I wrap so when I go to soldier, it slide into the layer of the brass and become almost a solid. You can't skip this because the brass collar is going to stick to the blade and the whole thing will get soldiered together and hold it solid.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-13_20-50-47_815.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-13_21-10-20_841.jpg?t=1318558221

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-13_21-31-27_656.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_21-11-58_179.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_21-12-09_630.jpg

robbiethepainter
10-15-2011, 09:35 AM
http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_23-09-26_505.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_23-17-36_923.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_23-43-19_243.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_23-43-35_502.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_23-40-46_545.jpg

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-10-14_23-20-31_139.jpg

dino
10-15-2011, 04:32 PM
Thanksnfornthe wonderful tutorial....Sorry, maybe I missed the part : how do u make the sword sheath?

dwing
10-15-2011, 04:38 PM
Awesome job and great tut.

robbiethepainter
10-15-2011, 05:16 PM
Yeah sorry about that. Its brass tubing I flatten to the correct shape. Then I bend it to the curve. It takes a little clean up to remove the nicks and stuff but heavy coats of paint make the surface nice and flat.

Cheungkinmen
10-15-2011, 06:53 PM
NICE WORK!. Thanks for sharing man.

Cdiesel09
10-15-2011, 07:14 PM
Cool. I always wondered where you got the swords from. Never knew you made them until now.

Maglor
10-15-2011, 07:20 PM
Groovy. :cool:

**16k**
10-17-2011, 02:19 AM
That's a really awesome tutorial! Thanks for that!!! :D

King Darkness
10-17-2011, 02:23 AM
Thats pretty god damn impressive :clap :clap :clap

EVILFACE
10-17-2011, 02:24 AM
That's pretty god damn impressive. :clap :clap :clap

MISFIT
10-17-2011, 04:28 AM
simply awesome!!!..that detail at that small a scale u must have elves workin for u!

siquisiri
10-21-2011, 10:54 PM
nice!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!

swtimes11
10-24-2011, 09:18 PM
Wow ... awesome skills.

adegregorio
10-24-2011, 09:30 PM
Great tutorial! Pics saved! :hi5:

SAB
10-24-2011, 09:35 PM
Awesome stuff !

Peteskywalker
11-29-2011, 05:06 PM
What thickness steel do you use for the bades?

William Shatners Toupee
11-30-2011, 02:44 PM
Awesome! very helpful! :clap:clap:clap

twik25
12-05-2011, 02:35 PM
HOW DID I MISS THIS!!?! Great tutorial! :clap :clap

Terminator_Fan_Game
12-07-2011, 11:46 PM
What thickness steel do you use for the bades?

:lecture:lecture:lecture
I would like to know this too. AWESOME work and thanks for the tutorial bro.

Peteskywalker
12-08-2011, 01:29 AM
:lecture:lecture:lecture
I would like to know this too. AWESOME work and thanks for the tutorial bro.

i think we want to know for the same reason :lol

got some from ebay with 0.5 thinkness so will see how it goes.

robbiethepainter
12-08-2011, 02:27 PM
Sorry guys. Busy as hell and dont get back to this thread very much. I don't know what the gauge is but here are pics with a ruler.

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-12-08_15-25-21_556.jpg?t=1323379524

http://i900.photobucket.com/albums/ac204/robbiethepainter/2011-12-08_15-24-55_612.jpg?t=1323379500

Mr. Green
12-31-2011, 11:59 PM
^^^ Looks like 1/32 inch thick. Interesting skills. Reminds me of making one from a metal tread that came off of an old tires. Ah, those were my ghettos days.

elar
02-26-2012, 04:45 PM
Fantastic tutorial!

Mr. EcKo
10-24-2012, 06:42 PM
Had to go back to this thread . JUST WOW

robbiethepainter
03-22-2013, 09:28 PM
Bump for question posted.